Automated Insert Mounting Using Adhesive Film Segmentation
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Solution Overview
Problem
Conventional methods for manufacturing furniture pieces, especially those using fiberglass or aluminum, require manual installation of cylindrical inserts, which is labor-intensive and not suitable for automated processes.
Innovation Solution
A method involving the application of an adhesive film on a tray with through-holes, followed by inserting the inserts and cutting the film to create individual adhesive circles, using a CO2 laser, allowing for automated mounting of inserts on standardized trays for use in integrated manufacturing cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual installation of inserts is used, then labor intensity is high, but automation capability is poor
Solution Approach 1:
The adhesive film is applied to the tray before the inserts are placed, and the film is cut into individual circles around each insert. This preliminary preparation of the adhesive structure enables automated pick-and-place operations by the robotic arm, transforming a manual task into an automated process while maintaining high productivity
Solution Approach 2:
The adhesive film acts as an intermediary between the tray and the inserts, providing a standardized interface that enables automated handling. The film's adhesive properties allow the robotic arm to reliably pick up inserts with pins inserted through them, solving the automation capability issue while maintaining production efficiency
2Productivity
If automated process is implemented, then productivity increases, but insert preparation complexity increases
Solution Approach 1:
The adhesive film is cut into individual separate circles around each insert, creating discrete, independently handled units. This segmentation simplifies the automated process by allowing the robotic arm to pick and place individual inserts without complex manipulation, reducing preparation complexity while maintaining high productivity
Solution Approach 2:
The adhesive film undergoes a parameter change from a continuous sheet to separated circular segments through laser cutting. This transformation creates optimal conditions for automated handling by providing clearly defined, separate adhesive areas for each insert, reducing the complexity of automated insert preparation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method automates the mounting of inserts, reducing labor costs and enabling their use in automated fabrication processes, enhancing productivity and reliability.
Implementation Method 1
Application of an adhesive film on one of the faces of a tray of inserts covering a plurality of through-holes and respective depressions; Insertion of one insert in each through-hole of the tray, through the face opposite the face of the adhesive film, securing a piece of the insert to this adhesive film
Implementation Method 2
Cutting out the adhesive film forming a plurality of single films associated to the inserts
Implementation Method 3
cooperating with a laser cutting device
Data Source
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AI summary
There is described a method of mounting inserts, comprising the following steps: •(i) Application of an adhesive film on one of the faces of an inserts tray (223) covering a plurality of through-holes (241) and respective depressions (242); •(ii) Insertion of an insert (230) in each through-hole (241) of the tray (223) from a face of the inserts tray (223) opposite that of the adhesive film, securing one surface of the insert (23) onto this adhesive film; •(iii) Cutout of the adhesive film forming a plurality of single films (245) associated with the inserts (230). There is further described an insert mounting device (300), comprising a holding table (314) held by a supporting base (311), the insert mounting device (300) further comprising a rotating tray holder (312), cooperating with a cutting system (313).